Lincoln Electric FlexCut 80 User manual

Operator’s Manua
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IM10197-B | Issue D ate Oct-16
© Lincoln Glo al, Inc. All Rights Reserved.
For use with machines having Code Num ers:
12249, 12589
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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
FlexCut ™80

THANK YOU FOR SELECTING
A QUALITY PRODUCT BY
LINCOLN ELEC TRIC.
PLEASE EXAMINE CARTON AND EQUIPMENT FOR
DAMAGE IMMEDIATELY
When this equipment is shipped, title passes to the purchaser
upon receipt by the carrier. Consequently, claims for material
damaged in shipment must be made by the purchaser against the
transportation company at the time the shipment is received.
SAFETY DEPENDS ON YOU
incoln arc welding and cutting equipment is designed and built
with safety in mind. However, your overall safety can be increased
by proper installation ... and thoughtful operation on your part.
DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT
WITHOUT READING THIS MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly,
think before you act and be careful.
This statement appears where the information must be followed
exactly to avoid serious personal injury or loss of life.
This statement appears where the information must be followed
to avoid minor personal injury or damage to this equipment.
KEEP YOUR HEAD OUT OF THE FUMES.
DON’T get too close to the arc.
Use corrective lenses if necessary
to stay a reasonable distance
away from the arc.
READ and obey the Safety Data
Sheet (SDS) and the warning label
that appears on all containers of
welding materials.
USE ENOUGH VENTILATION or
exhaust at the arc, or both, to
keep the fumes and gases from
your breathing zone and the general area.
IN A LARGE ROOM OR OUTDOORS, natural ventilation may be
adequate if you keep your head out of the fumes (See below).
USE NATURAL DRAFTS or fans to keep the fumes away
from your face.
If you de velop unusual symptoms, see your supervisor.
Perhaps the welding atmosphere and ventilation system
should be checked.
EAR CORRECT EYE, EAR &
BODY PROTECTION
PROTECT your eyes and face with welding helmet
properly fitted and with proper grade of filter plate
(See ANSI Z49.1).
PROTECT your body from welding spatter and arc
flash with protective clothing including woolen
clothing, flame-proof apron and gloves, leather
leggings, and high boots.
PROTECT others from splatter, flash, and glare
with protective screens or barriers.
IN SOME AREAS, protection from noise may be appropriate.
BE SURE protective equipment is in good condition.
Also, wear safety glasses in work area
AT ALL TIMES.
SPECIAL SITUATIONS
DO NOT WELD OR CUT containers or materials which previously
had been in contact with hazardous substances unless they are
properly cleaned. This is extremely dangerous.
DO NOT WELD OR CUT painted or plated parts unless special
precautions with ventilation have been taken. They can release
highly toxic fumes or gases.
Additional precautionary measures
PROTECT compressed gas cylinders from excessive heat,
mechanical shocks, and arcs; fasten cylinders so they cannot fall.
BE SURE cylinders are never grounded or part of an
electrical circuit.
REMOVE all potential fire hazards from welding area.
ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR
IMMEDIATE USE AND KNOW HOW TO USE IT.
WARNING
CAUTION
Safety 01 of 04 - 06/15/2016

SECTION A:
WARNINGS
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel En ines
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and other
reproductive harm.
Gasoline En ines
The engine exhaust from this product contains chemicals known
to the State of California to cause cancer, birth defects, or other
reproductive harm.
ARC ELDING CAN BE HAZARDOUS. PROTECT
YOURSELF AND OTHERS FROM POSSIBLE SERIOUS
INJURY OR DEATH. KEEP CHILDREN A AY.
PACEMAKER EARERS SHOULD CONSULT ITH
THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For
additional safety information, it is strongly recommended
that you purchase a copy of “Safety in Welding & Cutting -
ANSI Standard Z49.1” from the American Welding Society,
P.O. Box 351040, Miami, Florida 33135 or CSA Standard
W117.2-1974. A Free copy of “Arc Welding Safety” booklet
E205 is available from the incoln Electric Company,
22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION,
MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE POWERED
EQUIPMENT.
1.a. Turn the engine off before troubleshooting
and maintenance work unless the
maintenance work requires it to be running.
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes outdoors.
1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from
vaporizing on contact with hot engine parts
and igniting. Do not spill fuel when filling
tank. If fuel is spilled, wipe it up and do not start engine until
fumes have been eliminated.
1.d. Keep all equipment safety guards, covers
and devices in position and in good repair.
Keep hands, hair, clothing and tools away
from V-belts, gears, fans and all other
moving parts when starting, operating or
repairing equipment.
1.e. In some cases it may be necessary to remove safety guards to
perform required maintenance. Remove guards only when
necessary and replace them when the maintenance requiring
their removal is complete. Always use the greatest care when
working near moving parts.
1.f. Do not put your hands near the engine fan. Do not attempt to
override the governor or idler by pushing on the throttle control
rods while the engine is running.
1.g. To prevent accidentally starting gasoline engines while turning
the engine or welding generator during maintenance work,
disconnect the spark plug wires, distributor cap or magneto wire
as appropriate.
1.h. To avoid scalding, do not remove the radiator
pressure cap when the engine is hot.
ELECTRIC AND
MAGNETIC FIELDS MAY
BE DANGEROUS
2.a. Electric current flowing through any conductor
causes localized Electric and Magnetic Fields (EMF).
Welding current creates EMF fields around welding cables
and welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health effects
which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and work
cables. If the electrode cable is on your right side, the
work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as pos-
sible to the area being welded.
2.d.5. Do not work next to welding power source.
SAFETY
Safety 02 of 04 - 06/15/2016

ELECTRIC SHOCK
CAN KILL.
3.a. The electrode and work (or ground) circuits are
electrically “hot” when the welder is on. Do
not touch these “hot” parts with your bare skin or wet clothing.
Wear dry, hole-free gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full area
of physical contact with work and ground.
In addition to the normal safety precautions, if
welding must be performed under electrically
hazardous conditions (in damp locations or while
wearing wet clothing; on metal structures such as
floors, gratings or scaffolds; when in cramped
positions such as sitting, kneeling or lying, if there
is a high risk of unavoidable or accidental contact
with the workpiece or ground) use the following
equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic welding
gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection should
be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical (earth)
ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of electrode
holders connected to two welders because voltage
between the
two can be the total of the open circuit voltage of both
welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see It ems 6.c. and 8.
ARC RAYS CAN BURN.
4.a. Use a shield with the proper filter and cover plates to protect your
eyes from sparks and the rays of the arc when welding or
observing open arc welding. Headshield and filter lens should
conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant material
to protect your skin and that of your helpers from the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES
CAN BE DANGEROUS.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these fumes and gases.
When welding, keep your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep fumes and gases
away from the breathing zone. hen welding hardfacing
(see instructions on container or SDS) or on lead
or cadmium plated steel and other metals or
coatings which produce highly toxic fumes, keep
exposure as low as possible and within applicable
OSHA PEL and ACGIH TLV limits using local
exhaust or mechanical ventilation unless exposure
assessments indicate otherwise. In confined
spaces or in some circumstances, outdoors, a
respirator may also be required. Additional
precautions are also required when welding
on galvanized steel.
5. b. The operation of welding fume control equipment is affected by
various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker exposure
level should be checked upon installation and periodically
thereafter to be certain it is within applicable OSHA PE and
ACGIH T V limits.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations. The
heat and rays of the arc can react with solvent vapors to form
phosgene, a highly toxic gas, and other irritating products.
5.d. Shielding gases used for arc welding can displace air and
cause
injury or death. Always use enough ventilation, especially in
confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
Safety Data Sheet (SDS) and follow your employer’s safety
practices. SDS forms are available from your welding
distributor or from the manufacturer.
5.f. Also see item 1.b.
SAFETY
Safety 03 of 04 - 06/15/2016

WELDING AND CUTTING
SPARKS CAN CAUSE
FIRE OR EXPLOSION.
6.a. Remove fire hazards from the welding area. If
this is not possible, cover them to prevent the welding sparks
from starting a fire. Remember that welding sparks and hot
materials from welding can easily go through small cracks and
openings to adjacent areas. Avoid welding near hydraulic lines.
Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site, special
precautions should be used to prevent hazardous situations.
Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1)
and the operating information for the equipment being used.
6.c. When not welding, make certain no part of the electrode circuit is
touching the work or ground. Accidental contact can cause
overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances inside.
They can cause an explosion even though they have been
“cleaned”. For information, purchase “Recommended Safe
Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous Substances”,
AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil free
protective garments such as leather gloves, heavy shirt, cuffless
trousers, high shoes and a cap over your hair. Wear ear plugs
when welding out of position or in confined places. Always wear
safety glasses with side shields when in a welding area.
6.g. Connect the work cable to the work as close to the welding area
as practical. Work cables connected to the building framework or
other locations away from the welding area increase the
possibility of the welding current passing through lifting chains,
crane cables or other alternate circuits. This can create fire
hazards or overheat lifting chains or cables until they fail.
6.h. Also see item 1.c.
6.I. Read and follow NFPA 51B “Standard for Fire Prevention During
Welding, Cutting and Other Hot Work”, available from NFPA, 1
Batterymarch Park, PO box 9101, Quincy, MA 022690-9101.
6.j. Do not use a welding power source for pipe thawing.
CYLINDER MAY EXPLODE IF
DAMAGED.
7.a. Use only compressed gas cylinders containing
the correct shielding gas for the process used
and properly operating regulators designed for
the gas and pressure used. All hoses, fittings,
etc. should be suitable for the application and
maintained in good condition.
7.b. Always keep cylinders in an upright position securely chained to
an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected
to physical damage.
• A safe distance from arc welding or cutting operations
and any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand tight
except when the cylinder is in use or connected for use.
7.g. Read and follow the instructions on compressed gas cylinders,
associated equipment, and CGA publication P-l, “Precautions for
Safe Handling of Compressed Gases in Cylinders,” available from
the Compressed Gas Association, 14501 George Carter Way
Chantilly, VA 20151.
FOR ELECTRICALLY
POWERED EQUIPMENT.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National Electrical
Code, all local codes and the manufacturer’s recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Refer to
http://www.lincolnelectric.com/safety
for additional safety information.
SAFETY
Safety 04 of 04 - 06/15/2016

SAFETY
General Precautions
Whereas plasma cutting has been used safely for years, it does
require certain precautions to ensure the safety of the operator and
other people around the equipment. The following safety information
must be provided to each person who will operate, observe, perform
maintenance, or work in close proximity to this piece of equipment.
Installation, operation, and repairs made to the system should only be
performed by qualified personnel. The system makes use of both A.C.
and D.C. circuitry for operation. Fatal shock hazard does exist.
Exercise extreme caution while working on the system. Safety decals
On the power supply should not be removed.
ULTRAVIOLET RADIATION
PROTECTION
Plasma cutting produces ultraviolet radiation similar to a welding arc.
This ultraviolet radiation can cause skin and eye burns. For this
reason, it is essential that proper protection be worn. The eyes are
best protected by using safety glasses or a welding helmet with an
AWS No. 12 shade or ISO 4850 No. 13 shade, which provides
protection up to 400 amperes. All exposed skin areas should be
covered with flame-retardant clothing. The cutting area should also
be prepared in such a way that ultraviolet light does not reflect. Walls
and other surfaces should be painted with dark colors to reduce
reflected light. Protective screens or curtains should be installed to
protect additional workers in the area from ultraviolet radiation.
NOI E PROTECTION
The system generates high noise levels while cutting. Depending on
the size of the cutting area, distance from the cutting torch, and arc
current cutting level, acceptable noise levels may be exceeded.
Proper ear protection should be used as defined by local or national
codes. See Section 2 for noise emission levels.
TOXIC FUME PREVENTION
Care should be taken to ensure adequate ventilation in the cutting
area. Some materials give off toxic fumes that can be harmful or fatal
to people in the vicinity of the cutting area. Also, some solvents
decompose and form harmful gases when exposed to ultraviolet
radiation. These solvents should be removed from the area prior to
cutting. alvanized metal can produce harmful gases during the
cutting process. Ensure proper ventilation and use breathing
equipment when cutting these materials.
Certain metals coated with or containing lead, cadmium, zinc,
beryllium, and mercury produce harmful toxins. Do not cut these
metals unless all people subjected to the fumes wear proper air
breathing equipment.
ELECTRIC HOCK PREVENTION
The system uses high open circuit voltages that can be
fatal. Extreme care should be used when operating or
performing maintenance on the system. Only qualified personnel
should service the system. Observe the following guidelines to protect
against electric shock:
• A wall-mounted disconnect switch should be installed and fused
according to local and national electrical codes. The disconnect
switch should be located as close as possible to the power supply
so it can be turned off in case of an emergency.
• The primary power cord should have a 600 volt minimum rating in
order to protect the operator. In addition, it should be sized
according to local and national electrical codes. Inspect the primary
power cord frequently. Never operate the system if the power cord
is damaged in any way.
• Make sure the primary power ground wire is connected at the input
power ground location on the power supply. Make sure the
connection is securely tightened.
• Make sure the positive output (work ground) of the power supply is
connected to a bare metal area on the cutting table. A driven
ground rod should be placed no further than five feet from this
connection. Make sure this ground point on the cutting table is
used as the star ground point for all other ground connections.
• Inspect the torch leads frequently. Never use the system if the leads
are damaged in any way.
• Do not stand in wet, damp areas when operating or performing
maintenance on the system.
• Wear insulated gloves and shoes while operating or performing
maintenance on the system.
• Make sure the system is switched off at the wall disconnect before
servicing the power supply or torch.
• Never change torch consumable parts unless main power to the
system is switched off at the power supply or wall disconnect.
• Do not attempt to remove any parts from beneath the torch when
cutting. Remember that the workpiece forms the current path back
to the power supply.
• Never bypass the safety interlock devices.
• Before removing any of the covers, switch the system off at the wall
disconnect. Wait at least five (5) minutes before removing any
cover. This will give the capacitors inside the unit time to discharge.
See Section 5 for additional safety precautions.
• Never operate the system without all of the covers in place. See
Section 5 for additional safety precautions.
• Preventive maintenance should be performed daily to avoid
possible safety hazards.
2
FLEXCUT™ 80 SAFETY

3
FLEXCUT™ 80
FIRE PREVENTION
When using the system , it is necessary to exercise good
judgment. While cutting, the arc produces sparks that could cause a
fire if they fall on flammable materials. Make sure that all flammable
materials are a suitable distance away from the cutting area. All
flammable liquids should be at least 40 feet away from the cutting
area, preferably stored in a metal cabinet. Plasma cutting should
never be attempted on containers that contain flammable materials.
Make sure that fire extinguishers are readily accessible in the cutting
area.
EXPLO ION PREVENTION
The system uses compressed gases. Use proper
techniques when handling compressed gas cylinders and other
compressed gas equipment. Observe the following guidelines to
protect against explosion:
• Never operate the system in the presence of explosive gases or
other explosive materials.
• Never cut pressurized cylinders or any closed container.
• When using a water table and cutting aluminum under water or
with water touching the underside at the aluminum plate,
hydrogen gas is produced. This hydrogen gas may collect under
the plate and explode during the cutting process. Make sure the
water table is properly aerated to help prevent the accumulation
of hydrogen gas.
• Handle all gas cylinders in accordance with safety standards
published by the U.S. Compressed as Association (C A),
American Welding Society (AWS), Canadian Standards
Association (CSA), or other local or national codes.
• Compressed gas cylinders should be maintained properly. Never
attempt to use a cylinder that is leaking, cracked, or has other
signs of physical damage.
• All gas cylinders should be secured to a wall or rack to prevent
accidental knock over.
• If a compressed gas cylinder is not being used, replace the
protective valve cover.
• Never attempt to repair compressed gas cylinders.
• Keep compressed gas cylinders away from intense heat, sparks,
or flames.
• Clear the compressed gas cylinder connection point by opening
the valve momentarily prior to installing a regulator.
• Never lubricate compressed gas cylinder valves or pressure
regulators with any type of oil or grease.
• Never use a compressed gas cylinder or pressure regulator for
any purpose other than which it is intended.
• Never use a pressure regulator for any gas other than which it is
intended.
• Never use a pressure regulator that is leaking or has other signs
of physical damage.
• Never use any gas hose that is leaking or has other signs of
physical damage.
HEALTH UPPORT EQUIPMENT
The system creates electric and magnetic fields that
may interfere with certain types of health support
equipment, such as pacemakers. Any person who uses a pacemaker
or similar item should consult a doctor before operating, observing,
maintaining, or servicing the system. Observe the following guidelines
to minimize exposure to these electric and magnetic fields:
• Stay as far away from the~power supply, torch, and torch leads
as possible.
• Route the torch leads as close as possible to the work ground
cable.
• Never place your body between the torch leads and work ground
cable. Keep the work ground cable and the torch leads on the
same side of your body.
• Never stand in the center of a coiled up set of torch leads or work
ground cable.
SAFETY

FLEXCUT™ 80
Safety Standards Booklet Index
For further information concerning safety practices to be exercised
with plasma arc cutting equipment, please refer to the following
publications:
1. AWS Standard AWN, Arc Welding and Cutting Noise, obtainable
from the American Welding Society, 550 NW LeJeune Road, Miami,
FL 33126.
2. AWS Standard C5.2, Recommended Practices for Plasma Arc
Cutting, obtainable from the American Welding Society, 550 NW
LeJeune Road, Miami, FL 33126.
3. AWS Standard FSW, Fire Safety in Welding and Cutting, obtainable
from the American Welding Society, 550 NW LeJeune Road, Miami,
FL 33126.
4. AWS Standard F4.1, Recommended Safe Practices for Preparation
for Welding and Cutting of Containers and Piping, obtainable from
the American Welding Society, 550 NW LeJeune Road, Miami, FL
33126.
5. AWS Standard ULR, Ultraviolet Reflectance of Paint, obtainable
from the American Welding Society, 550 NW LeJeune Road, Miami,
FL 33126.
6. AWS I ANSI Standard Z49.1, Safety in Welding, Cutting, and Allied
Processes, obtainable from the American Welding Society, 550 NW
LeJeune Road, Miami, FL 33126.
7. ANSI Standard Z41.1 , Standard For Men's Safety-Toe Footwear,
obtainable from the American National Standards Institute, 11 West
42nd Street, New York, NY 10036.
8. ANSI Standard Z49.2, Fire Prevention in the Use of Cutting and
Welding Processes, obtainable from the American National
Standards Institute, 11 West 42nd Street, New York, NY 10036.
9. ANSI Standard Z87.1, Safe Practices For Occupation and
Educational Eye and Face Protection, obtainable from the American
National Standards Institute, 11 West 42nd Street, New York, NY
10036.
10. ANSI Standard Z88.2, Respiratory Protection, obtainable from the
American National Standards Institute, 11 West 42nd Street, New
York, NY 10036.
11. OSHA Standard 29CFR 1910.252, Safety and Health Standards,
obtainable. from the U.S. overnment Printing Office, Washington,
D.C. 20402.
12. NFPA Standard 51 , Oxygen - Fuel as Systems for Welding,
Cutting, and Allied Processes, obtainable from the National Fire
Protection Association, 1 Batterymarch Park, Quincy, MA 02269.
13. NFPA Standard 51 B, Cutting and Welding Processes, obtainable
from the National Fire Protection Association, 1 Batterymarch
Park, Quincy, MA 02269.
14. NFPA Standard 70, National Electrical Code, obtainable from the
National Fire Protection Association, 1 Batterymarch Park, Quincy,
MA 02269.
15. C A booklet P-1 , Safe Handling of Compressed ases in
Containers, obtainable from the Compressed as Association,
1725 Jefferson Davis Highway, Suite 1004, Arlington, VA 22202.
16. C A booklet P-14, Accident Prevention in Oxygen-Rich and
Oxygen-Deficient Atmospheres, obtainable from the Compressed
as Association, 1725 Jefferson Davis Highway, Suite 1004,
Arlington, VA 22202.
17. C A booklet TB-3, Hose Line Flashback Arrestors, obtainable from
the Compressed as Association, 1725 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202.
18. CSA Standard W117 .2, Safety in Welding, Cutting, and Allied
Processes, obtainable from Canadian Standards Association, 178
Rexdale Boulevard, Toronto, Ontario M9W IR3, Canada.
19. Canadian Electrical Code Part 1, Safety Standard for Electrical
Installations, obtainable from the Canadian Standards Association,
178 Rexdale Boulevard, Toronto, Ontario M9W 1 R3, Canada.
4
SAFETY

5
FLEXCUT™ 80
Table Of Contents
Page
General Description....................................................................................................................................
Preheat Temperature For Plasma Cutting ............................................................................................6
Duty Cycle...........................................................................................................................................6
User Responsibility..............................................................................................................................6
Design Features And Advantages ........................................................................................................6
Installation ..................................................................................................................................Section A
Select Suitable Location...................................................................................................................A-1
Lifting ............................................................................................................................................A-2
Stacking ..........................................................................................................................................A-2
Tilting ............................................................................................................................................A-2
High Frequency Interference Protection ...........................................................................................A-2
Input Connection..............................................................................................................................A-2
Machine rounding..........................................................................................................................A-2
Input Plug Installation ......................................................................................................................A-3
Power Cord Replacement.................................................................................................................A-3
Engine Driven enerator ..................................................................................................................A-3
as Supply Requirements................................................................................................................A-3
Connecting The as Supply .............................................................................................................A-4
Output Connections .........................................................................................................................A-4
Operation ..................................................................................................................................Section B
Controls And Settings ......................................................................................................................B-2
Hand Cutting .................................................................................................................................B-4
Hand Cutting Charts.........................................................................................................................B-5
Mechanized Cutting.......................................................................................................................B-10
Mechanized Cutting Charts............................................................................................................B-12
Consumable Life............................................................................................................................B-16
Cut Quality.....................................................................................................................................B-16
Options/Accessories...................................................................................................................Section C
Maintenance ...............................................................................................................................Section D
Daily Procedures .............................................................................................................................D-1
Monthly Procedures.........................................................................................................................D-1
Troubleshooting ..........................................................................................................................Section E
Wiring Diagrams..........................................................................................................................Section F
Wiring Diagram ............................................................................................................................F-1
Dimension Print............................................................................................................................F-2
Parts List .........................................................................................................parts.lincolnelectric.com
Content/details may be changed or updated without notice. For most current Instruction Manuals, go to
parts.lincolnelectric.com.

FLEXCUT™ 80
GENERAL DESCRIP ION
The FLEXCUT™ 80 is a constant current, continuous control plasma
cutting power source. It provides superior and reliable starting
characteristics, cutting visibility and arc stability. The control system
has a safety mechanism to insure that the nozzle and electrode are in
place before cutting or gouging. This is extremely important due to
the high voltages involved.
The FLEXCUT™ 80 comes standard with an air regulator and
pressure gauge. The machine also comes with an input power cord.
Torches and consumables are included with FLEXCUT™ 80
One-Paks®, so that cutting can begin right out of the box.
Consumables and torches can also be ordered as individual
packages.
The FLEXCUT™ 80 initiates the plasma arc with a simple, yet
reliable, contact start mechanism. This system eliminates many of the
failure problems associated with hi-frequency start systems.
PREHEA EMPERA URE FOR PLASMA CU ING
Preheat temperature control is not necessary in most applications
when plasma arc cutting or gouging. Preheat temperature control
may be necessary on high carbon alloy steels and heat treated
aluminum for crack resistance and hardness control. Job conditions,
prevailing codes, alloy level, and other considerations may also
require preheat temperature control. The following minimum preheat
temperature is recommended as a starting point. Higher temperatures
may be used as required by the job conditions and/or prevailing
codes. If cracking or excessive hardness occurs on the cut face,
higher preheat temperature may be required. The recommended
minimum preheat temperature for plate thickness up to 1/2"
(12.7mm) is 70°F (21.1°C).
DU Y CYCLE
The duty cycle of a plasma machine is the percentage of time in a 10
minute cycle at which the operator can operate the machine at rated
cutting current.
Example: 80% duty cycle means that it is possible to cut for 8
minutes, followed by 2 minutes of machine idling.
Refer to the Technical Specification section for more information
about the machine rated duty cycles.
USER RESPONSIBILI Y
Because design, fabrication, erection and cutting variables affect the
results obtained in applying this type of information, the serviceability
of a product or structure is the responsibility of the user. Variation
such as plate chemistry, plate surface condition (oil, scale), plate
thickness, preheat, quench, gas type, gas flow rate and equipment
may produce results different than those expected. Some adjustments
to procedures may be necessary to compensate for unique individual
conditions. Test all procedures duplicating actual field conditions.
DESIGN FEA URES AND ADVAN AGES
The FLEXCUT™ 80 design makes plasma cutting uncomplicated. This
list of design features and advantages will help you understand the
machine's total capabilities so that you can get maximum use from
your machine.
- Light weight and portable design for industrial use.
- Continuous control, 25 - 80 amps.
- Reliable touch start mechanism for plasma arc initiation.
- Rapid arc restrike for fast cutting of expanded metal.
- Input over voltage protection.
- Bright 5.0 second timed pilot arc.
- as purge selection.
- Air regulator and pressure gage included.
- Internal water separator included.
- Parts-in-Place mechanism to detect proper installation of
consumables and torch.
- Preflow/Postflow timing. Preflow is eliminated if arc is re-
initiated in Postflow.
- Thermostatic Protection.
- Solid state over-current protection.
- Patented electrode, nozzle and shield cap for optimum cooling,
cut quality and long life.
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